Shipping containers for batteries

ABSTRACT

Shipping containers for batteries are described herein. An example shipping container includes a base defining a cavity, a lid to be coupled to a top of the base to substantially seal the cavity, and an absorbent pad disposed within the cavity to absorb liquid from the battery if the battery leaks.

FIELD OF THE DISCLOSURE

This disclosure relates generally to containers and, more particularly,to shipping containers for batteries.

BACKGROUND

Objects having hazardous materials are required to have specialpermitting and pay special fees for shipping and handling. For example,wet cell batteries typically contain liquid acids and/or other corrosivechemicals that can be hazardous if leaked from the battery. Therefore,current wet cell batteries are classified as hazardous material objectsand cannot be shipped without providing a hazardous declaration orspecial permitting, as well as special packaging and handling because ofthe danger of potential spillage of the contents of the battery. Thesedocuments are relatively expensive and require the use of specialshipping carriers that are separate from normal shipping channels.

SUMMARY

An example shipping container for a battery disclosed herein includes abase defining a cavity, a lid to be coupled to a top of the base tosubstantially seal the cavity, and an absorbent pad disposed within thecavity to absorb liquid from the battery if the battery leaks.

Another example shipping container for a battery disclosed hereinincludes a base defining a cavity, a lid to be coupled to a top of thebase to substantially seal the cavity, and a plurality of foam insertsthat are disposable in the cavity to change a size of the cavity forreceiving the battery. One or more of the foam inserts have an absorbentpad to absorb liquid from the battery if the battery leaks.

Another example shipping container for a battery disclosed hereinincludes a base defining a cavity, a lid to be coupled to a top of thebase to substantially seal the cavity, a base foam insert disposed inthe cavity to reduce vibrations and impacts to the battery when thebattery is disposed in the shipping container, and means for absorbingliquid from the battery if the battery leaks.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top, left, front perspective view of an example shippingcontainer constructed in accordance with the teachings of thisdisclosure.

FIG. 2 is a bottom, right, rear perspective view of the example shippingcontainer of FIG. 1.

FIG. 3 is a perspective view of the example shipping container of FIG. 1with an example lid in an open position. FIG. 3 also shows an examplebattery that may be stored and/or transported in the example shippingcontainer and an example bag in which the example battery may bedisposed.

FIG. 4 is a perspective view of an example base foam insert that may beutilized in the example shipping container of FIG. 1.

FIG. 5 is a cross-sectional view showing the example battery of FIG. 3within the example shipping container with the example lid in the closedposition.

FIGS. 6A and 6B are a top and bottom perspective views, respectively, ofan example top foam insert that may be used with the example shippingcontainer of FIG. 1.

FIGS. 7 and 8 are example base foam inserts that may be used with theexample shipping container of FIG. 1.

FIG. 9 shows an example multi-piece foam insert kit that may be usedwith the example shipping container of FIG. 1.

The figures are not to scale. Instead, the thickness of the layers orregions may be enlarged in the drawings. In general, the same referencenumbers will be used throughout the drawing(s) and accompanying writtendescription to refer to the same or like parts. As used in this patent,stating that any part (e.g., a layer, film, area, region, or plate) isin any way on (e.g., positioned on, located on, disposed on, or formedon, etc.) another part, indicates that the referenced part is either incontact with the other part, or that the referenced part is above theother part with one or more intermediate part(s) located therebetween.Connection references (e.g., attached, coupled, connected, and joined)are to be construed broadly and may include intermediate members betweena collection of elements and relative movement between elements unlessotherwise indicated. As such, connection references do not necessarilyinfer that two elements are directly connected and in fixed relation toeach other. Stating that any part is in “contact” with another partmeans that there is no intermediate part between the two parts. Althoughthe figures show layers and regions with clean lines and boundaries,some or all of these lines and/or boundaries may be idealized. Inreality, the boundaries and/or lines may be unobservable, blended,and/or irregular.

Descriptors “first,” “second,” “third,” etc. are used herein whenidentifying multiple elements or components which may be referred toseparately. Unless otherwise specified or understood based on theircontext of use, such descriptors are not intended to impute any meaningof priority, physical order or arrangement in a list, or ordering intime but are merely used as labels for referring to multiple elements orcomponents separately for ease of understanding the disclosed examples.In some examples, the descriptor “first” may be used to refer to anelement in the detailed description, while the same element may bereferred to in a claim with a different descriptor such as “second” or“third.” In such instances, it should be understood that suchdescriptors are used merely for ease of referencing multiple elements orcomponents.

DETAILED DESCRIPTION

Certain materials classified as hazardous by the United Nations (UN)Testing cannot be shipped through regular shipping channels in the U.S.according to the Department of Transportation (DOT) regulations and theInternational Air Transport Authority (IATA) regulations. Instead, DOTand IATA regulations require hazardous materials to be prepared andshipped by a certified shipper (a certified Haz Mat shipper) and requirepayment of hazardous shipment fees by the shipper/carrier. Similarregulations may be encountered domestically within other counters and/orinternationally between multiple countries. This problem is commonlyencountered with wet cell batteries that contain liquid acids and othercorrosive materials. For example, wet cell batteries such asnickel-cadmium (NiCd) are commonly used in various transportationindustries (e.g., on aircraft, vehicles, such as cars, trains, etc.).These batteries have a relatively long lifespan. Therefore, it is commonto ship or transport the batteries for routine service or maintenance.However, shipping these batteries requires special permitting (e.g.,hazardous declarations) and handling because the batteries containliquids, such as acids, bases, and/or other corrosive chemicals. Thisbecomes quiet expensive for the transportation companies, batterymanufacturers, and/or battery servicers.

Today, wet cell batteries are transported in corrugated cardboard boxesor polycarbonate plastic containers. However, as mentioned above, thesecontainers are required to be shipped as hazardous materials, whichrequires special permitting, extra fees, and separate shipping channels.Known containers are not always properly sized for the battery and,thus, the battery may move within the container during shipping. In someinstances, a battery may rupture and leak within the container. Even ifthe lid on the container is substantially sealed, the liquid may stilleventually seep or leak from the container. Therefore, shippinghazardous materials is risky for the shippers/carriers, who can beliable for personal fines and penalties for improper preparation,marking, and/or accidents.

Disclosed herein are example shipping containers that may be used tostore and/or transport hazardous material objects, such as wet cellbatteries. The examples disclosed herein provide a substantiallydurable, leak-proof shipping container. Should an object such as abattery become damaged and/or otherwise leak within the container, thecontainer prevents any liquid from leaking out of the container. Theexample shipping containers disclosed herein have passed several testsby approved testing agencies for vibration, drop, stacking andstability, and excessive heat and cold. For instance, the exampleshipping containers disclosed herein have passed standards of the DOTTitle 49 CFR, Performance Oriented Packaging Stands, Section 178, andare certified under International Maritime Dangerous Goods (IMDG),Technical Instructions for the Safe Transport of Dangerous Goods by Air(ICAO), and International Air Transport Association (IATA) regulationsand the UN Recommendations on the Transport of Dangerous Good.Therefore, with proper approval from the DOT and/or other governmentagencies, the example shipping containers disclosed herein would besuitable for shipping hazardous materials via non-hazardous shippingchannels (e.g., regular ground and/or air shipping). This wouldsignificantly reduce the expenses, time, and liability associated withshipping these batteries and/other hazardous materials. This would alsoenable aviation companies to more easily ship their batteries for properservicing, thereby prolonging the life of the batteries.

An example shipping container disclosed herein includes a base and a lidthat is hingedly coupled to the base. The base defines a cavity in whichan object, such as a battery, can be disposed. The example container mayinclude one or more latches or locks to lock the lid in a closedposition, thereby substantially sealing the battery within thecontainer. The example container includes one or more absorbent pads orliners that can be disposed within the cavity of the container. Theabsorbent pad(s) is/are constructed of absorbent material, such aspolypropylene cloth or other materials, that is configured to readilyabsorb and hold liquid within the material of the absorbent pad(s)without significant deterioration (e.g., the absorbent material issolvent resistant). The absorbent pad(s) may be disposed along one ormore surfaces within the cavity such as along one or more foam inserts.Should the battery become damaged and/or otherwise leak, the liquid fromthe battery is absorbed by the absorbent pad(s). This reduces orprevents free liquid from accumulating in the container and sloshingaround, which may otherwise leak from the seal between the lid and thebase.

As mentioned above, in some examples, the example shipping containerincludes one or more foam inserts disposed in the cavity to help supportand reduce or prevent movement of the battery relative to the shell. Theabsorbent pad(s) may be coupled or applied along one or more surfaces ofthese foam inserts. The foam inserts may be coupled to the container viaadhesives (e.g., glue, re-appliable adhesives, etc.). The foam insertsmay be sized to pass UN Testing requirements. Examples of UN Testingstandards and other regulatory and industry standards that are met bythe example shipping containers are disclosed in further detail herein.If a spill occurs, the foam inserts with the pads may be discarded andnew foam inserts with absorbent pads can be installed in the container.Therefore, the examples disclosed herein provide a durable, leak-proofcontainer that can be used to store and/or transport materials and whichmay be suitable as a shipping container for transporting hazardousmaterials via traditional shipping channels.

FIGS. 1 and 2 illustrate an example shipping container 100 constructedin accordance with the teachings of this disclosure. FIG. 1 is a top,left, front perspective view of the example container 100 and FIG. 2 isa bottom, right, rear perspective view of the example container 100. Theexample shipping container 100 may be used to store and/or transport oneor more objects, including objects having materials designated ashazardous materials by shipping and/or transportation authorities, suchas wet cell batteries.

In the illustrated example, the container 100 includes a shell 101(e.g., a case) formed by a base 102 and a lid 104. The base 102 is fivesided structure that defines a cavity (shown in FIG. 3) for receiving anobject (e.g., a battery). The lid 104 is to be coupled to a top 105 ofthe base 102 to substantially seal the cavity. In some examples, the lid104 is movably coupled to the base 102 via one or more hinges. Inparticular, in this example, the lid 104 is coupled to the base 102 viathree hinges 200 (one of which is referenced in FIG. 2) that allows thelid 104 to move between a closed position (as shown in FIGS. 1 and 2)and an open position (shown in FIG. 3). As shown in FIGS. 1 and 2, thebase 102 has a first side wall 106 (a left wall), a second side wall 202(a right wall) opposite the first side wall 106, a third side wall 108(a front wall), a fourth side wall 204 (a rear wall) opposite the thirdside wall 108, and a bottom side wall 206. When the lid 104 is in theclosed position, the lid 104 forms a top side wall that substantiallyseals the cavity within the base 102.

The base 102 and/or the lid 104 may be constructed of a relatively lightbut rigid, durable material, such as high-density polyethylene,low-density polyethylene (e.g., EXXON Mobil brand linear low-densitypolyethylene (LLDPE) 8460), and/or polycarbonate plastic. In otherexamples, the base 102 and/or the lid 104 may be constructed of othermaterials. In some examples, the base 102 is a single-molded piece, andthe lid 104 is a single-molded piece. In other examples, the base 102and/or the lid 104 may be constructed of multiple parts that are coupledtogether.

To lock the lid 104 in the closed position, the container 100 mayinclude one or more latches. For example, as shown in FIG. 1, thecontainer 100 includes a first latch 110 and a second latch 112 on thethird side wall 108. In this example, the first and second latches 110,112 are twist actuated draw latches (sometimes referred to as butterflylatches). The first and second latches 110, 112 mate with correspondingstrikes 114, 116 (also referred to as catches or keepers) on a frontedge 118 of the lid 104. In other examples, other types of latches maybe used, such as a slide-release buckle and/or a metal over-center drawlatch. In other examples, the first and/or second latches 110, 112 maybe in different locations (e.g., one latch on the first side wall 106and another latch on the second side wall 202). In some examples, one ormore additional latches or fasteners may be used to help lock and sealthe lid 104 in the closed position. For example, the container 100includes a first fastener 120 on the first side wall 106 and a secondfastener 208 on the second side wall 202. The first and second fasteners120, 208 help lock and seal the lid 104 against the base 102. In otherexamples, the container 100 may include more or fewer fasteners and/orthe fastener(s) may be disposed in other locations.

While in this example the lid 104 is hingedly coupled to the base 102,in other examples the lid 104 may be completely removable from the base102. In such an example, one or more latches may be located on thefourth side wall 204 of the base 102. In still other examples, the lid104 may be movably coupled to or completely removable from the base 102in other manners.

As shown in FIGS. 1 and 2, the container 100 has a first handle 122coupled to the first side wall 106 and a second handle 210 coupled tothe second side wall 202. The first and second handles 122, 210 may beused for carrying the container 100. The first and second handles 122,210 are pivotably coupled to the respective side walls 106, 202. In someexamples, the first and second handles 122, 210 may be spring loadedhandles. The first and second handles 122, 210 may be disposed inrecesses formed in the respective side walls 106, 202. In otherexamples, the container 100 may have more or fewer handles. In someexamples, the container 100 does not have any handles.

In some examples, the base 102 and/or the lid 104 provide features toenable multiple containers to be stacked vertically. For example, asshown in FIGS. 1 and 2, the lid 104 has raised corner portions 124 (oneof which is referenced in FIG. 1) and the bottom side wall 206 of thebase 102 has corner recesses 212 (one of which is referenced in FIG. 2)that are complementary to the raised corner portions 124. When multiplecontainers are vertically stacked, the raised corner portions 124 of onecontainer fits within the corner recesses 212 of another container. Thismating helps prevent the containers from falling.

In the illustrated example, the lid 104 has a planar section 126. Insome examples, shipping instructions or other indicia may be printed on,engraved in, and/or coupled to the planar section 126. For example, ifthe container 100 is approved by the DOT and/or other agencies forshipping through non-hazardous shipping channels, a specialized shippingpermit may be disposed on the planar section 126. Additionally oralternatively, instructions for properly installing one or more foaminserts (disclosed in further detail here) and sealing the container 100may be provided on the planar section 126. In other examples, suchinstructions and/or indicia may be provided on other side surfaces ofthe container 100.

FIG. 3 shows the container 100 with the lid 104 in the open position.The lid 104 has been rotated about the hinges 200 (FIG. 2). Also shownin FIG. 3 is an example wet cell battery 300 that may be stored and/ortransported in the container 100. The battery 300 may be an aircraftbattery, such as a NiCd battery, that contains liquid acids, bases,and/or other corrosive chemicals. In this example, the battery 300 isgenerally cube shaped. However, in other examples, the battery 300 mayhave different shapes and/or sizes. FIG. 3 also shows an example bag302. In some examples, the battery 300 is be placed in the bag 302 andthe bag 302 is sealed before placing the battery 300 in the container100. The bag 302 helps to contain any leakage of liquid from the battery300. In other examples, a bag is not used.

As shown in FIG. 3, the base 102 defines a cavity 304 in which thebattery 300 is to be disposed. In the illustrated example, the container100 includes a base foam insert 306 disposed in the cavity 304. The basefoam insert 306 reduces vibrations and impacts on the battery 300 whilestoring and transporting the battery 300 in the container 100. In someexamples, the base foam insert 306 is constructed of a high-density,closed cell, polyethylene or polystyrene foam. In other examples, thebase foam insert 306 may be constructed of other foam materials. In someexamples, the base foam insert 306 is coupled to an inner surface of thebase 102 via an adhesive, such as glue or a re-appliable/reusableadhesive. In other examples, the base foam insert 306 may be coupled tothe base 102 via other techniques (e.g., hook and loop fasteners).Additionally or alternatively, the base foam insert 306 may be held inthe base 102 via friction fit. The base foam insert 306 maysubstantially fill the bottom of the cavity 304. In the illustratedexample, the base foam insert 306 does not extend up to a top of thebase 102. In other examples, the base foam insert 306 may be sizedtaller or shorter. In some examples, the base foam insert 306 is sizedto meet minimum requirements for passing UN Testing.

In the illustrated example, the base foam insert 306 has a recess 308 toreceive the battery 300. The recess 308 may be dimensioned to receivethe bottom of the battery 300 snuggly (e.g., the inner dimensions of therecess may be slightly less than the outer dimensions of the battery300). As such, when the battery 300 is disposed in the recess 308, thebattery 300 causes the base foam insert 306 to compress, which induces aholding friction on the battery 300. FIG. 4 shows an isolated view ofthe base foam insert 306.

Once the battery 300 is inserted into the base 102, the lid 104 may beclosed and locked via the first and second latches 110, 112. In someexamples, one or more foam inserts are disposed on a bottom side 310 ofthe lid 104. For example, as shown in FIG. 3, the container 100 includesa first lid foam insert 312 and a second lid foam insert 314 that aredisposed on the bottom side 310 of the lid 104. The first and second lidfoam inserts 312, 314 may be constructed of the same material as thebase foam insert 306 or a different foam material. In some examples, thefirst and second lid foam inserts 312, 314 are coupled to the bottomside 310 of the lid 104 via an adhesive, such as glue. In some examples,when the battery 300 is disposed in the recess 308 and the lid 104 isclosed, the first and second lid foam inserts 312, 314 may contact a topof the battery 300 and compress. This reduces or prevents verticalmovement of the battery 300 in the container 100. In some examples, thethickness of the first and second lid foam inserts 312, 314 correspondsto the minimum thickness to accommodate a largest sized battery forwhich the container 100 can pass UN Testing. Additional foam inserts maybe used to fill excess space when smaller batteries are shipped. In thisexample, the second lid foam insert 314 is spaced from the first lidfoam insert 312. In some examples, the first and second lid foam inserts312, 314 are space apart to accommodate a bracket or other structure onthe top of the battery 300. In other examples, the first and second lidfoam inserts 312, 314 may be in contact with each other. In someexamples only one lid foam insert is utilized, and such a single lidfoam insert may cover the entire bottom side 310 of the lid 104. Inother examples, multiple lid foam inserts are utilized. The lid foaminserts may be stacked and/or arranged in various configurations.

In some examples, the container 100 includes one or more seals between atop rim of the base and a bottom rim of the lid. For example, as shownin FIG. 3, the container 100 includes a first seal 316 (e.g., a rubberseal, a sealing gasket) and a second seal 317 around a top rim 318 ofthe base 102 and a third seal 320 disposed in a groove 321 formed in abottom rim 322 of the lid 104. When the lid 104 is attached to the top105 of the base 102, the first and second seals 316, 317 engage thebottom rim 322 of the lid 104 and the third seal 320 engages the top rim318 of the base 102, thereby forming a sealing interface tosubstantially seal the cavity 304 and prevent liquid from leaking out ofthe container 100 between the base 102 and the lid 104. Example sealsthat may be implemented as the first, second, and third seals 316, 317,320 are disclosed in U.S. Pat. No. 7,063,212, titled “Multiple SealStorage and Transport Container,” filed Sep. 19, 2002, which is herebyincorporated by reference in its entirety. In other examples, other sealconfigurations may be used (e.g., one seal on the bottom rim 322 of thelid 104 and one seal on the top rim 318 of the base 102, only one sealon the bottom rim 322 of the lid 104, only one seal on the top rim 318of the base 102, etc.).

The example container 100 includes one or more pads or liners ofabsorbent material disposed in the cavity 304 to absorb any liquidleaked from the battery 300. In particular, many batteries containliquid acids, bases, and other corrosive chemicals. Should the battery300 become damaged, the liquid could leak from the battery 300. Looseliquid in the container 100 could eventually seep or leak out frombetween the seals 316, 317, 320. In particular, while the bag 302 and/orthe seals 316, 317, 320 may be able to contain small amounts of liquidin the container 100, the bag 302 and/or the seals 316, 317, 320 may notbe able to effectively contain larger leaks that result in large volumesof liquid. Therefore, the absorbent pad(s) absorb(s) the liquid andtherefore reduce or prevent free liquid from accumulating and sloshingaround the inside of the container 100.

In the illustrated example, a top of the base foam insert 306 is linedwith an example absorbent pad 324. The absorbent pad 324 is also shownin FIG. 4. Referring to FIG. 4, the absorbent pad 324 covers a topsurface 400 of the base foam insert 306 and surfaces of the base foaminsert defining the recess 308. In some examples, the absorbent pad 324is flexible and can conform to the shape of the underlying object. Insome examples, the absorbent pad 324 is constructed of polypropylenecloth. In other examples, the absorbent pad 324 may be constructed ofanother type of absorbent material (e.g., silica gel packs, desiccant).In some examples, the absorbent pad 324 is coupled to the base foaminsert 306 via an adhesive, such as glue (e.g., CC-4144A clearadhesive), a re-appliable adhesive, and/or double-sided tape. In otherexamples, the absorbent pad 324 may be coupled to the base foam insert306 via other manners (e.g., hook and loop fasteners). Should the liquidin the battery 300 leak, the liquid is absorbed by the absorbent pad324, which prevents free liquid from accumulating and sloshing aroundthe inside of the container 100. While in this example the absorbent pad324 only covers a top of the base foam insert 306, in other examples,one or more absorbent pads may be provided one or more other surfaces(e.g., the side surfaces, the bottom surface, etc.) of the base foaminsert 306.

In addition to or as an alternative to the absorbent pad 324 on the basefoam insert 306, one or more absorbent pad may be provided in otherlocations within the cavity 304. For example, first and second absorbentpads 326, 328 are coupled to the respective first and second lid foaminserts 312, 314. The first and second absorbent pads 326, 328 may beconstructed of the same material as the absorbent pad 324 or a differentmaterial. The first and second absorbent pads 326, 328 function the sameas the absorbent pad 324 to absorb any liquid that potentially comesinto contact with the first and/or second lid foam inserts 312, 314.Therefore, in this example, a portion of all six sides of the battery300 are covered with absorbent pads. As such, if a leak occurs, theabsorbent pads 324, 326, 328 can effectively absorb the liquid andprevent free liquid from accumulating in the container 100. In additionto or as an alternative to the absorbent pads 324, 326, 328, one or moreother absorbent pads may be provided along other surfaces of the cavity304. For example, one or more absorbent pads may be disposed along oneor more of the inner surfaces of the side walls of the base 102.

FIG. 5 is a cross-sectional view of the battery 300 in the container100. The bag 302 is not shown in FIG. 5. However, if the bag 302 isused, it is understood that the bag 302 would be disposed around thebattery 300, between the battery 300 and the foam inserts 306, 312, 314.

As shown in FIG. 5, the battery 300 is disposed in the recess 308 of thebase foam insert 306. The recess 308 (considering the thickness of theabsorbent pad 324) is sized to snuggly receive the battery 300. When thebattery 300 is disposed in the recess 308, the battery 300 may slightlycompress the absorbent pad 324 and/or the base foam insert 306. The basefoam insert 306 prevents or reduces side-to-side movement of the battery300 relative to the container 100 as well as, in some examples,up-and-down movement of the battery 300 in the container 100. A top 500of the battery 300 is engaged with the first and second absorbent pads326, 328. The first and second foam lid inserts 312, 314 and theabsorbent pads 326, 328 are sized such that when the lid 104 is closedand locked, the top 500 of the battery 300 contacts the absorbent pads326, 328 and causes a compression of the absorbent pads 326, 328 and/orthe first and second lid foam inserts 312, 314. This reduces or preventsup-and-down movement of the battery 300 relative to the container 100.Therefore, the battery 300 is held securely in the container 100.

Should the battery 300 become damaged and/or otherwise leak, the liquidfrom the battery 300 is absorbed by the absorbent pads 324, 326, 328.When the container 100 reaches its desired destination, a person candiscard the foam inserts 306, 312, 314 and install new foam inserts(with new absorbent pads) into the cavity 304 before shipping anotherbattery. In other examples, just the absorbent pads can be removed andreplaced with new absorbent pads. Thus, the container 100 is reusableand therefore environmentally friendly.

In some examples, the amount of absorbent pad material used in thecontainer 100 is sufficient to completely absorb the entire liquidcontents of the battery 300. As such, if there is a full rupture andleakage of the battery 300, all of the liquid is absorbed by theabsorbent pads. This ensures that no liquid can leak from the container100, which renders the example container 100 suitable for traditional(non-hazardous) shipping channels (if permitted by the DOT). While theabsorbent pads are designed to absorb liquid, the foam inserts (e.g.,the base foam insert 306, the first and second lid foam inserts 312,314, the top foam insert 600, etc.) are constructed of material that isnot designed to absorb liquid. As such, if there is liquid in thecontainer 100, the liquid does not compromise the structural integrityof the foam inserts. In this manner, the foam inserts can continue tofunction to support and cushion movement of the battery 300 in thecontainer 100.

The example shipping container 100 has been passed a number ofregulatory and industry standards as listed in Tables 1 and 2 below. Theexample shipping container 100 may also meet other regulatory andindustry standards not listed below.

TABLE 1 Regulatory References Passed 49 CFR¹ UN² UNDG³ ICAO⁴ IATA⁵October 2018 20^(th) 2018 2019-2020 60^(th) Test Edition Edition EditionEdition Edition Drop: 178.603 6.1.5.3 6.1.5.3 6; 4.3 6.3.3 Stacking:178.606 6.1.5.6 6.1.5.6 6; 4.6 6.3.6 Vibration: 178.608 — — 4; 1.1.1 &5.0.2.7 4; 1.1.4 ¹United States Department of Transportation Code ofFederal Regulations (CFR) Title 49, Transportation, Parts 100-185 ²TheUnited Nations Recommendations on the Transport of Dangerous Goods -Model Regulations (UN - Orange Book) ³International Maritime DangerousGoods Code (IMDG) ⁴Technical Instructions for the Safe Transport ofDangerous Goods by Air (ICAO) ⁵International Air Transport Association(IATA) Dangerous Goods Regulations

TABLE 2 Industry Standards Passed Drop: ASTM⁶ Standard Test Method forDrop Test of D5276: Loaded Containers by Free Fall ASTM⁶ Standard TestMethod for the Preparation of D7790: Plastic Packagings ContainingLiquids for United Nations (UN) Drop Testing ISO⁷ 2248: Packaging -Complete, Filled Transport Packages - Vertical Impact Test by DroppingStacking: ASTM⁶ Standard Test Method for Compression D4577: Resistanceof a Container Under Constant Load ISO⁷ 2234: Packaging - Complete,Filled Transport Packages - Stacking Test using Static Load Vibration:ASTM⁶ Standard Test Method of Vibration Testing D999: of ShippingContainers ISO⁷ 2247 Packaging - Complete, Filled Transport Packages -Vibration Test at Fixed Low Frequency ⁶American Society for Testing andMaterials (ASTM) ⁷International Organization for Standardization (ISO)

In some examples, the container 100 can include a top foam insert thatmay be used to fill excess space between the top 500 of the battery 300and the lid 104 if a smaller sized battery is used. FIGS. 6A and 6B aretop and bottom perspective views of an example top foam insert 600. Thetop foam insert 600 has a recess 602. Before closing the lid 104 of thecontainer 100, the top foam insert 600 may be placed over the top 500 ofthe battery 300 such that the top 500 of the battery 300 is disposed inthe recess 602. When the lid 104 is closed, the top foam insert 600fills excess space between the top 500 of the battery 300 and the firstand second lid foam inserts 312, 314, which helps reduce or preventmovement of the battery 300 relative to the container 100. The top foaminsert 600 can be constructed of the same foam material as the base foaminsert 306 or may be constructed of another foam material. In theillustrated example, an absorbent pad 604 (e.g., polypropylene cloth) iscoupled to the top foam insert 600. The absorbent pad 604 further helpsto absorb liquid that may leak from the battery 300. The top foam insert600 provides additional surface area for an absorbent pad, therebyincreasing the total absorbent pad area in the cavity 304.

Different sized base foam inserts may be used in the container 100depending on the size of the battery 300. FIGS. 7 and 8 illustrate otherexample base foam inserts 700, 800 that may be used in the container 100in place of the base foam insert 306. The base foam insert 700 of FIG. 7has a larger recess with higher walls, whereas the base foam insert 800of FIG. 8 has a shallower recess with lower walls. The base foam inserts700, 800 have absorbent pads 702, 802, respectively, that are similar tothe base foam insert 306 and used to absorb liquids from a battery.

FIG. 9 illustrates an example multi-piece foam insert kit 900 that canbe used with the container 100. The kit 900 includes a plurality of foaminserts that are disposable in the cavity 304 to change the size of thecavity 304 for receiving a battery. The foam inserts can be arranged orconfigured to accommodate various sized batteries, thereby creating auniversal container. As such, a user can arrange one or more inserts ofthe kit 900 within the base 102 to accommodate a desired battery size.

In the illustrated example, the kit 900 includes a base foam insert 902having a recess 904. The base foam insert 902 can be disposed in thecavity 304 of the container 100, similar to the base foam insert 306. Insome examples, the recess 904 is sized to accommodate a largest sizebattery. The kit 900 also includes various sized foam inserts 906, 908,910, 912, 914, 916. One or more of the foam inserts 906-916 can beplaced along the sides, top, and/or bottom of the battery to ensure thebattery is snuggly fit within the container 100. In some examples, thefoam inserts 902, 906-916 are constructed of a high-density, closedcell, polyethylene or polystyrene foam. In other examples, the foaminserts 902, 906-916 may be constructed of other foam materials. One ormore of the foam inserts 906-916 can be stacked. The foam inserts906-916 can be attached to each other and/or the walls of the base 102by pressure fit by size, adhesives (e.g., glue), and/or any otherfastening means. In some examples, one or more of the foam inserts 902,906-916 has an absorbent pad for absorbing liquid. For example, each ofthe foam inserts 902, 906-916 of FIG. 9 has a respective absorbent pad918, 920, 922, 924, 926, 928, 930 along at least one surface of therespective foam insert. The absorbent pads 918-930 may be coupled therespective foam inserts via an adhesive, such as glue (e.g., CC-4144Aclear adhesive), a re-appliable adhesive, and/or double-sided tape. Assuch, if a battery leaks within the container 100, the absorbent pads918-930 absorb the liquid. In some examples, more than one side orsurface of each of the foam inserts 902, 906-916 is lined with anabsorbent pad. The kit 900 may include any number of foam inserts, andthe foam inserts may be any shape and/or size. Multiple ones of the samesize/shape insert may be provided, as long as the sizes meet minimumrequirements for passing UN Testing. Therefore, instead of needingdifferent sized base foam inserts and lid foam inserts for each sizebattery, a single universal foam insert kit can be provided with eachcontainer shell. Then, a user can configure the foam inserts accordingto the size of the battery to be shipped.

While many of the example shipping containers disclosed here aredescribed in connection with storing or transporting batteries, it isunderstood that the example shipping containers disclosed herein can beused to store and/or transport any other object, hazardous ornon-hazardous.

“Including” and “comprising” (and all forms and tenses thereof) are usedherein to be open ended terms. Thus, whenever a claim employs any formof “include” or “comprise” (e.g., comprises, includes, comprising,including, having, etc.) as a preamble or within a claim recitation ofany kind, it is to be understood that additional elements, terms, etc.may be present without falling outside the scope of the correspondingclaim or recitation. As used herein, when the phrase “at least” is usedas the transition term in, for example, a preamble of a claim, it isopen-ended in the same manner as the term “comprising” and “including”are open ended. The term “and/or” when used, for example, in a form suchas A, B, and/or C refers to any combination or subset of A, B, C such as(1) A alone, (2) B alone, (3) C alone, (4) A with B, (5) A with C, (6) Bwith C, and (7) A with B and with C. As used herein in the context ofdescribing structures, components, items, objects and/or things, thephrase “at least one of A and B” is intended to refer to implementationsincluding any of (1) at least one A, (2) at least one B, and (3) atleast one A and at least one B. Similarly, as used herein in the contextof describing structures, components, items, objects and/or things, thephrase “at least one of A or B” is intended to refer to implementationsincluding any of (1) at least one A, (2) at least one B, and (3) atleast one A and at least one B. As used herein in the context ofdescribing the performance or execution of processes, instructions,actions, activities and/or steps, the phrase “at least one of A and B”is intended to refer to implementations including any of (1) at leastone A, (2) at least one B, and (3) at least one A and at least one B.Similarly, as used herein in the context of describing the performanceor execution of processes, instructions, actions, activities and/orsteps, the phrase “at least one of A or B” is intended to refer toimplementations including any of (1) at least one A, (2) at least one B,and (3) at least one A and at least one B.

As used herein, singular references (e.g., “a”, “an”, “first”, “second”,etc.) do not exclude a plurality. The term “a” or “an” entity, as usedherein, refers to one or more of that entity. The terms “a” (or “an”),“one or more”, and “at least one” can be used interchangeably herein.Furthermore, although individually listed, a plurality of means,elements or method actions may be implemented by, e.g., a single unit orprocessor. Additionally, although individual features may be included indifferent examples or claims, these may possibly be combined, and theinclusion in different examples or claims does not imply that acombination of features is not feasible and/or advantageous.

From the foregoing, it will be appreciated that example shippingcontainers have been disclosed that are durable and leak-proof and,thus, are suitable for storing and/or transporting objects designated asbeing or having hazardous materials, such as wet cell batteries. Theexample shipping containers include one or more absorbent pads that canabsorb liquid within the container to substantially reduce or preventfree liquid from accumulating in the example container. If authorized bythe DOT, the example shipping containers disclosed herein may besuitable for shipping hazardous materials via non-hazardous shippingchannels (e.g., regular ground and/or air shipping). This wouldsignificantly reduce the expenses, time, and liability associated withshipping these batteries and/other hazardous materials.

Example methods, apparatus, and articles of manufacture for storing ortransporting objects, such as batteries, are disclosed herein. Differentaspects of the examples disclosed herein can be combined in otherexamples. Further examples and combinations thereof include thefollowing clauses.

Clause 1 is a shipping container for a battery. The shipping containerincludes a base defining a cavity, a lid to be coupled to a top of thebase to substantially seal the cavity, and an absorbent pad disposedwithin the cavity to absorb liquid from the battery if the batteryleaks.

Clause 2 includes the shipping container of Clause 1, wherein theabsorbent pad is constructed of polypropylene cloth.

Clause 3 includes the shipping container of Clauses 1 or 2, furtherincluding a base foam insert disposed in the cavity. The base foaminsert has a recess to receive the battery. The absorbent pad is coupledto the base foam insert.

Clause 4 includes the shipping container of Clause 3, wherein theabsorbent pad covers a top surface of the base foam insert and surfacesof the base foam insert defining the recess.

Clause 5 includes the shipping container of Clauses 3 or 4, wherein theabsorbent pad is coupled to the base foam insert via an adhesive.

Clause 6 includes the shipping container of any of Clauses 3-5, whereinthe base foam insert is constructed of high-density polyethylene.

Clause 7 includes the shipping container of any of Clauses 3-6, furtherincluding a first lid foam insert disposed on a bottom side of the lid.

Clause 8 includes the shipping container of Clause 7, wherein theabsorbent pad is a first absorbent pad, further including a secondabsorbent pad coupled to the first lid foam insert.

Clause 9 includes the shipping container of Clause 8, further includinga second lid foam insert disposed on the bottom side of the lid. Thesecond lid foam insert is spaced from the first lid foam insert.

Clause 10 includes the shipping container of Clause 9, further includinga third absorbent pad coupled to the second lid foam insert.

Clause 11 includes the shipping container of Clause 10, furtherincluding a top foam insert to be disposed between a top of the batteryand the first and second lid foam inserts.

Clause 12 includes the shipping container of Clause 11, furtherincluding a fourth absorbent pad coupled to the top foam insert.

Clause 13 includes the shipping container of any of Clauses 1-12,wherein the lid is movably coupled to the base via one or more hinges,further including: one or more latches to lock the lid in a closedposition, one or more seals between a top rim of the base and a bottomrim of the lid, and one or more handles coupled to the base.

Clause 14 is a shipping container for a battery. The shipping containerincludes a base defining a cavity, a lid to be coupled to a top of thebase to substantially seal the cavity, and a plurality of foam insertsdisposable in the cavity to change a size of the cavity for receivingthe battery. One or more of the foam inserts has an absorbent pad toabsorb liquid from the battery if the battery leaks.

Clause 15 includes the shipping container of Clause 14, wherein theabsorbent pad is constructed of polypropylene cloth.

Clause 16 includes the shipping container of Clauses 14 or 15, whereinone of the plurality of foam inserts includes a base foam insert to bedisposed in the cavity. The base foam insert has a recess to receive thebattery.

Clause 17 includes the shipping container of any of Clauses 14-16,wherein the plurality of foam inserts are constructed of high-densitypolyethylene.

Clause 18 is a shipping container for a battery. The shipping containerincludes a base defining a cavity, a lid to be coupled to a top of thebase to substantially seal the cavity, a base foam insert disposed inthe cavity to reduce vibrations and impacts to the battery when thebattery is disposed in the shipping container, and means for absorbingliquid from the battery if the battery leaks.

Clause 19 includes the shipping container of Clause 18, wherein theabsorbing means is coupled to the base foam insert.

Clause 20 includes the shipping container of Clauses 18 or 19, whereinthe absorbing means is a first absorbing means, further including: a lidfoam insert disposed on a bottom side of the lid, and second means forabsorbing the liquid, the second absorbing means coupled to the lid foaminsert.

Although certain example methods, apparatus and articles of manufacturehave been disclosed herein, the scope of coverage of this patent is notlimited thereto. On the contrary, this patent covers all methods,apparatus and articles of manufacture fairly falling within the scope ofthe claims of this patent.

The following claims are hereby incorporated into this DetailedDescription by this reference, with each claim standing on its own as aseparate embodiment of the present disclosure.

What is claimed is:
 1. A shipping container for a battery, the shippingcontainer comprising: a base defining a cavity; a base foam insertdisposed in the cavity, the base foam insert having a recess to receivethe battery; a lid to be coupled to a top of the base to substantiallyseal the cavity; a lid foam insert disposed on a bottom side of the lid;a first absorbent pad disposed within the cavity to absorb liquid fromthe battery if the battery leaks, the first absorbent pad coupled to thebase foam insert; and a second absorbent pad coupled to the lid foaminsert.
 2. The shipping container of claim 1, wherein the firstabsorbent pad is constructed of polypropylene cloth.
 3. The shippingcontainer of claim 1, wherein the first absorbent pad covers a topsurface of the base foam insert and surfaces of the base foam insertdefining the recess.
 4. The shipping container of claim 1, wherein thefirst absorbent pad is coupled to the base foam insert via an adhesive.5. The shipping container of claim 1, wherein the base foam insert isconstructed of high-density polyethylene.
 6. The shipping container ofclaim 1, wherein the lid foam insert is a first lid foam insert, theshipping container further including a second lid foam insert disposedon the bottom side of the lid, the second lid foam insert spaced fromthe first lid foam insert.
 7. The shipping container of claim 6, furtherincluding a third absorbent pad coupled to the second lid foam insert.8. The shipping container of claim 7, further including a top foaminsert to be disposed between a top of the battery and the first andsecond lid foam inserts.
 9. The shipping container of claim 8, furtherincluding a fourth absorbent pad coupled to the top foam insert.
 10. Theshipping container of claim 1, wherein the lid is movably coupled to thebase via one or more hinges, further including: one or more latches tolock the lid in a closed position; one or more seals between a top rimof the base and a bottom rim of the lid; and one or more handles coupledto the base.
 11. The shipping container of claim 1, wherein the secondabsorbent pad is constructed of polypropylene cloth.
 12. The shippingcontainer of claim 1, wherein the lid foam insert is constructed ofhigh-density polyethylene.
 13. The shipping container of claim 1,wherein the lid foam insert is coupled to the bottom side of the lid viaan adhesive.
 14. A shipping container for a battery, the shippingcontainer comprising: a base defining a cavity; a lid to be coupled to atop of the base to substantially seal the cavity; a plurality of foaminserts disposable in the cavity to change a size of the cavity forreceiving the battery, one or more of the foam inserts having a firstabsorbent pad to absorb liquid from the battery if the battery leaks; alid foam insert disposed on a bottom side of the lid; and a secondabsorbent pad coupled to the lid foam insert.
 15. The shipping containerof claim 14, wherein at least one of the first absorbent pad or thesecond absorbent pad is constructed of polypropylene cloth.
 16. Theshipping container of claim 14, wherein one of the plurality of foaminserts includes a base foam insert to be disposed in the cavity, thebase foam insert having a recess to receive the battery.
 17. Theshipping container of claim 14, wherein the plurality of foam insertsare constructed of high-density polyethylene.
 18. The shipping containerof claim 14, wherein the lid foam insert is a first lid foam insert, theshipping container further including: a second foam insert disposed on abottom side of the lid and spaced apart from the first lid foam insert;and a third absorbent pad coupled to the second lid foam insert.
 19. Ashipping container for a battery, the shipping container comprising: abase defining a cavity; a lid to be coupled to a top of the base tosubstantially seal the cavity; a base foam insert disposed in the cavityto reduce vibrations and impacts to the battery when the battery isdisposed in the shipping container; a lid foam insert disposed on abottom side of the lid; first means for absorbing liquid from thebattery if the battery leaks; and second means for absorbing the liquid,the second absorbing means coupled to the lid foam insert.
 20. Theshipping container of claim 19, wherein the first absorbing means iscoupled to the base foam insert.